System and method for making molded articles

Abstract

A system and method for automating the making of molded articles formed from a substrate and a fabric material, wherein the fabric material is positioned over a mold surface and a substrate material is injected between the fabric material and the mold surface such that the substrate material hardens and bonds with the fabric material forming the molded article.

1 . A molding system for creating a molded article having a substrate and a fabric material positioned over the substrate, the molding system comprising:
 a first component having a cavity slider with a contour portion;   a second component having a core insert with a mold surface;   wherein the molding system operates such that said core insert is moved into molding position with said contour portion and fabric material is positioned between said contour portion and said mold surface; and   wherein substrate material is injected along said mold surface between said mold surface and the fabric material to form a substrate for the fabric material.   
     
     
         2 . The molding system of  claim 1  wherein said second component further includes an internal slider that operates to move into to press the fabric material against said contour portion such that one or more openings are formed in the substrate. 
     
     
         3 . The molding system of  claim 1  wherein said second component includes a fabric positioning and maintaining system for maintaining the fabric material in place while substrate material is being injected along said mold surface. 
     
     
         4 . The molding system of  claim 1  wherein said second component includes one or more locator pins and core locator blocks and said first component includes cavity locator blocks, wherein said one or more locator pins, said core locator blocks and said cavity locator blocks cooperate to direct and maintain the fabric material in place while substrate material is being injected along said mold surface. 
     
     
         5 . The molding system of  claim 1  further comprising a cutting tool for cuffing the fabric material. 
     
     
         6 . The molding system of  claim 1  further comprising a master controller that operates to control the operation of the molding system. 
     
     
         7 . A molding system for creating a molded article having a substrate and a fabric material positioned over the substrate, the molding system comprising:
 a first component having a clamp plate supporting a cavity slider, wherein said cavity slider having a contour portion and wherein said cavity slider has a closed position and an open position, wherein said cavity slider is in said closed position when attaching the fabric material to the substrate forming a molded component and is in said open position when said molded component is removed from said molded component;   a second component having a clamp plate for supporting a core insert, said core insert having a mold surface and an internal slider that operates to move into and out of engagement with said mold surface; and   an injector and an injector channel for directing substrate material along said mold surface;   wherein said first component and said second component has a first position such that said first component and said second component are separated for receiving fabric material and has a second position such that the fabric material is positioned between said contour portion and said mold surface; and   wherein substrate material is injected into said injector surface such that the substrate material travels along said mold surface between said mold surface and the fabric material to form a substrate bonded to the fabric material.   
     
     
         8 . The molding system of  claim 7  wherein said second component further includes an internal slider that operates to move into to press the fabric material against said contour portion such that one or more openings are formed in the substrate. 
     
     
         9 . The molding system of  claim 7  wherein said second component includes a fabric positioning and maintaining system for maintaining the fabric material in place while substrate material is being injected along said mold surface. 
     
     
         10 . The molding system of  claim 7  wherein said second component includes one or more locator pins and core locator blocks and said first component includes cavity locator blocks, wherein said one or more locator pins, said core locator blocks and said cavity locator blocks cooperate to direct and maintain the fabric material in place while substrate material is being injected along said mold surface. 
     
     
         11 . The molding system of  claim 7  further comprising a cutting tool for cutting the fabric material. 
     
     
         12 . The molding system of  claim 7  further comprising a master controller that operates to control the operation of the molding system. 
     
     
         13 . A process for making a molded article having a fabric material bonded to a substrate comprising the steps of:
 moving fabric material into placement along a mold surface of a core insert of a second component;   moving a first component having a cavity slider with a contour portion such that the fabric material is between the contour portion and the mold surface;   moving an internal slider of the second component such that it is pressed against the surface of the fabric material;   injecting a substrate material such that it flows along the mold surface such that it forms a substrate bonded to the fabric material forming a prefinished molded article;   removing the prefinished molded article from placement along the mold surface; and   cutting the fabric material at the ends of the fabric material to form a finished molded article.   
     
     
         14 . The process of  claim 13  wherein the internal slider operates to prevent substrate material to flow along a portion of the mold surface thereby creating openings in the substrate. 
     
     
         15 . The process of  claim 13  wherein the substrate material has an outer edge and further comprising the step of folding the ends of the fabric material such that it covers the edge of the substrate.